Cellular cushion

ABSTRACT

A cellular cushion includes a base and a plurality of hollow cells coupled to the base. The base includes at least a first layer and a second layer. The first layer includes a substantially planar lower surface and an opposite upper surface. The second layer includes a substantially planar lower surface and an opposite substantially planar upper surface. The hollow cells extend outwardly from the first layer upper surface within at least one region. Each of the cells within the first region are coupled together in flow communication. Each of the cells includes a hollow body portion and an outer surface. The cells are spaced across the base such that the cell outer surfaces cooperate to define a contoured seat configured to cradle a portion of a user. An outer surface of at least some of the cells is at least one of oriented obliquely with respect to the base.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/179,859 filed Jul. 12, 2005, and now issued as U.S. Pat. No.7,350,251.

BACKGROUND OF THE INVENTION

This invention relates generally to cellular cushions, and moreparticularly, to cellular cushions used with seats.

The sport of motorcycling has grown to epic proportions, and iscontinuing to grow in popularity, as evidenced by, for example, thegrowing number of television programs dedicated to motorcycles and thesteady annual increase of motorcycle sales. A typical motorcycle ridemay last for several hours, or very often several days, coveringhundreds of miles. Despite the smoothness of the pavement and themotorcycle suspension, the motorcycle operator may still be subjected tovibrational stresses induced through the seat. Over time, the vibrationsmay lead to discomfort and fatigue.

Known seats for vehicles, such as motorcycles, usually have a supportingbase layer, a cushion layer, and an exterior cover layer. Traditionally,a molded cushion is formed on the base layer and a cover is stitched andfitted over the cushion. To facilitate alleviating the effects ofvibrational forces induced to the operator through the seat, at leastsome known motorcycle seats include additional padding within the seat.However, over time, because the operator of a motorcycle is primarily ina seated position for extended periods of time, the padding in suchseats may bottom out and the operator's weight may undesirably becomeconcentrated in the bonier portions of the individual's buttocks. Assuch, known motorcycle seats do not facilitate distributing anoperator's weight across the individual's buttocks.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a cellular cushion is provided. The cellular cushionincludes a base and a plurality of hollow cells coupled to the base. Thebase includes at least a first layer and a second layer. The first layerincludes a substantially planar lower surface and an upper surface thatis opposite the lower surface. The second layer includes a substantiallyplanar lower surface and a substantially planar upper surface that isopposite the second layer lower surface. The plurality of hollow cellsextend outwardly from the first layer upper surface within at least oneregion. Each of the plurality of cells within each region are coupledtogether in flow communication. Each of the plurality of cells comprisesa hollow body portion and an outer surface. The plurality of cells arespaced across the base such that the plurality of cell outer surfacescooperate to define a contoured seat configured to cradle a portion of auser. An outer surface of at least some of the plurality of cells is atleast one of oriented obliquely with respect to the base and isnon-planar.

In another aspect, a cellular cushion including a base and a pluralityof hollow cells coupled to the base is provided. The base includes atleast a first layer and a second layer. The first layer includes asubstantially planar lower surface and an upper surface that is oppositethe lower surface. The second layer includes a substantially planarlower surface and a substantially planar upper surface that is oppositethe second layer lower surface. The plurality of hollow cells extendoutwardly from the first layer upper surface within at least one region.Each of the plurality of cells within the at least one region arecoupled together in flow communication only with cells within thatregion. Each of the plurality of cells includes a hollow body portionand an outer surface. The plurality of cells are spaced across the basesuch that the plurality of cell outer surfaces cooperate to define acontoured seat that is configured to cradle a portion of a user. Anouter surface of at least some of the plurality of cells is at least oneof oriented obliquely with respect to the base and is non-planar. Atleast some of the plurality of cell outer surfaces are sloped in a firstdirection and at least some of the plurality of cell outer surfaces aresloped in a second direction that is opposite the first direction. Atleast some of the hollow cells in the at least one region have anon-circular cross-sectional profile.

In a further aspect, a cellular cushion including base, a plurality offirst hollow cells extending outwardly from the base, and a plurality ofsecond hollow cells extending outwardly from the base is provided. Thebase has a substantially planar lower surface and a substantially planarupper surface that is opposite the lower surface. The plurality of firsthollow cells extending outward from the base within the first region.The plurality of second hollow cells extending outward from the basewithin the second region. The plurality of first hollow cells in thefirst region are coupled together in flow communication independently ofthe plurality of second hollow cells within the second region. Each ofthe first and second hollow cells includes a hollow body portionextending from the base to an outer surface. At least some of the cellouter surfaces are oriented obliquely with respect to the base and aresloped in a first direction. At least some of the cell outer surfacesare oriented obliquely with respect to the base and are sloped in asecond direction that is substantially opposite the first direction. Atleast some of the plurality of first and second plurality have anon-circular cross-sectional shape.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an exemplary cellular cushion;

FIG. 2 is a front perspective view of the cellular cushion shown in FIG.1; and

FIG. 3 is a rear perspective view of the cellular cushion shown in FIG.1.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a plan view of an exemplary cellular cushion 10. FIG. 2 is afront perspective view of cellular cushion 10. FIG. 3 is a rearperspective view of cushion 10. Cushion 10 is flexible and as describedherein, is configured for use as an underlying support surface, such as,but not limited to, with a vehicle seat for use with, for example, amotorcycle, a bicycle, and/or a tractor, or for use within an officechair. Moreover, cushion 10 may be used as a back rest for use with aseat. In the exemplary embodiment, cushion 10 is shaped for use with amotorcycle seat. Cushion 10 is intended as exemplary only, and thus isnot intended to limit in any way the definition and/or meaning of theterms “cushion” or “seat”. Furthermore, although the invention isdescribed herein in association with a cushion for a vehicle, and morespecifically for use with a cushion for a motorcycle seat, it should beunderstood that the present invention is applicable to other cushiondesigns, as well as other cellular cushions. Accordingly, practice ofthe present invention is not limited to cellular cushions for motorcycleseats.

Cushion 10 includes a base 12 and a plurality of hollow cells 14extending outwardly from base 12. In the exemplary embodiment, base 12includes a forward side 16 and a rear side 18 connected together by apair of opposing sides 20 and 22. More specifically, in the exemplaryembodiment, cushion sides 20 and 22 extend outwardly from cushionforward side 16 to a respective elbow 24 and 26, and rear side 18extends arcuately between elbows 24 and 26. In an alternativeembodiment, base 12 may be any shape depending on the intended use ofcushion 10.

In the exemplary embodiment, base 12 is flexible and is formed from aplurality of layers 30 that are coupled together. In one embodiment,base 12 and cells 14 are formed from a flexible neoprene. Alternatively,base 12 and cells 14 are formed from any material that enables cellularcushion 10 to function as described herein. In the exemplary embodiment,a lower layer 40 and an outer or conformal layer 42 are bonded togetherto form base 12, as described in more detail herein. Alternatively, base12 may include any number of layers 30 depending on the desiredapplication of cellular cushion 10. For example, in an alternativeembodiment, base 12 may include at least three layers 30 wherein atleast one of the layers 30 is fabricated from a material that preventsthat specific layer 30 from bonding against the other layers. Moreover,in other alternative embodiments, base 12 includes more than threelayers 30.

In the exemplary embodiment, each cell 14 includes a body portion 50 andan outer surface 52 that is formed integrally with body portion 50. Eachcell 14 is hollow and has a defined volume therein. Furthermore, eachcell 14 has a height H measured between an upper surface 54 of base 12and cell outer surface 52. Moreover, and as described in more detailbelow, in the exemplary embodiment, outer layer 42 is formed integrallywith cells 14. Alternatively, cells 14 may be formed integrally withlower layer 40 or any other layer 30 within base 12. In a furtheralternative embodiment, cells 14 are coupled to base 12 using any knowncoupling method, such as, but not limited to, through an adhesiveprocess or a radio frequency (RF) welding process.

In the exemplary embodiment, conformal layer 42 is formed unitarily withcells 14 such that cells 14, as described in more detail below, areoriented within an arrangement 58 of air cells 14. In alternativeembodiments, cells 14 are arranged in other geometric arrangements. Inthe exemplary embodiment, cell arrangement 58 is symmetrical andincludes a plurality of inner support or small cells 60 and a pluralityof outer support or large cells 62. In other embodiments, arrangement 58is non-symmetrical. In the exemplary embodiment, cells 60 are positionedsubstantially symmetrically across conformal layer 42 within cellarrangement 58, such that adjacent cells 60 are separated by asubstantially equal distance D₁. In an alternative embodiment, cells 60are separated by variable distances, and/or cells 60 are oriented in anon-symmetrical arrangement.

More specifically, in the exemplary embodiment, cells 60 have a smallercross-sectional area and define a smaller volume than cells 62. Itshould be noted that the size, height, volume, number, orientation, andlocation of cells 14 within arrangement 58, and relative to cushion 10,are each variably selected, as described in more detail below, based onthe intended use or application of cushion 10, and to enable cushion 10to function as described herein. Moreover, the dimensions of cushion 10and of cells 14 are variably selected to accommodate a variety of humanbody sizes. In the exemplary embodiment, cells 62 are positionedgenerally between cells 60 and cushion sides 20 and 22, and cells 60 arearranged in a plurality of rows 64. In an alternative embodiment, cells60 are not arranged in rows 64. Rows 64 extend substantially across base12 between sides 20 and 22, and substantially between forward and rearsides 16 and 18, respectively. In an alternative embodiment, cells 60and 62 are arranged in other geometric configurations 58 relative tocushion 10.

In the exemplary embodiment, small cells 60 are each substantiallycylindrical and each respective small cell body portion 50 has asubstantially circular cross-sectional area. As such, each cell 60 hasthe same diameter D₂. In an alternative embodiment, a plurality ofdifferent-sized cells 60 extend from base 12. In a further alternativeembodiment, cells 60 may be non-cylindrical and/or have a non-circularcross-sectional profile. In another alternative embodiment, cushion 10does not include any cells 60 and/or any cells having a substantiallycircular cross-sectional profile. More specifically, in the exemplaryembodiment, within arrangement 58, a plurality of small cells 60(identified for more clarity in the Figures as 80) are oriented suchthat their outer surface 52 is substantially planar and is alignedsubstantially parallel to base upper surface 54, and a plurality ofsmall cells 60 (identified for more clarity in the Figures as 82) areoriented such that their generally planar outer surface 52 is obliquelyaligned with respect to base upper surface 54. In an alternativeembodiment, an outer surface 52 of each cell 60 is non-planar and/or isobliquely aligned with respect to base upper surface 54.

More specifically, within arrangement 58, at least some of cells 82(identified for more clarity in the Figures as cells 90) are orientedsuch that outer surface 52 is sloped towards a centerline 92 extendingthrough cushion 10 from forward side 16 to rear side 18, and at leastsome of cells 82 (identified for more clarity in the Figures as cells94) are oriented such that outer surface 52 is sloped away fromcenterline 92. Moreover, in the exemplary embodiment, within arrangement58 a height H of small cells 60 varies across cushion 10.

In the exemplary embodiment, cells 62 are positioned between cells 60and cushion sides 20 and 22, and have a generally larger cross-sectionalarea than cells 60. More specifically, in the exemplary embodiment,cushion 10 includes four cells 62 which are space along rear side 18from elbow 24 to elbow 26. In the exemplary embodiment, cells 62 aretri-lobe shaped and have an outer surface 52 that is slightly slopedtowards centerline 92.

Within arrangement 58, cushion cells 14 are oriented and spaced acrosscushion 10 to facilitate proving support to a seated user. Moreover,because the cell heights H are varied across cushion 10, and because ofthe various sizes of cells 14, cell outer surfaces 52 define a contouredseating surface 100 upon which the user sits and which is generally inconformance with the shape of the user's buttocks. Moreover, the cellheight H, arrangement 58, and the dimensions of cushion 10, cells 14,and arrangement 58 are variably selected to accommodate a variety ofhuman body sizes and differences in user body contours. For example, inthe exemplary embodiment, the orientation of cells 60 and 62 withinarrangement 58 enables a plurality of depressions 102 to be definedwithin surface 100. More specifically, in the exemplary embodiment, theorientation of cells 60 and 62 define ischial support areas 103, atrochanter area 104, a coccyx relief area 105, and a genital relief area106.

When cushion 10 is in use by a seated user, the air-filled cells 14deform under the user's weight to substantially equalize the forcesinduced to the user. When cushion 10 is in use by a seated user, cells14 deform under the user's weight to substantially equalize the forcesinduced to the user Generally, the combination of the orientation ofcell outer surfaces 52 with respect to base 12 and ischial support area102 allows the seated user to settle further into cushion 10 such thatthe user's buttocks are cradled and such that the user's weight isfacilitated to be more evenly distributed across cushion 10. Moreover,because ischial support area 102 is designed to be substantiallycentered beneath the seated user's ischial area, cells 14 within ischialsupport area 102 facilitate damping vibrational stresses induced to theuser's ischial area. Furthermore, the orientation of cell outer surfaces52 with respect to base 12 allows the user's thighs to extend over theforward edge 16 of cushion 10 with optimal comfort. As a result, thesitting support provided to the seated operator is facilitated to beincreased.

In the exemplary embodiment, cells 14 across cushion are not all coupledtogether in fluid flow communication, but rather, within arrangement 58cells 14 are defined into regions 108 of cells 14 that are coupledtogether in fluid flow communication with each other, as described inmore detail below. More specifically, in the exemplary embodiment,arrangement 58 includes two regions 108: a first region 110 and a secondregion 112 (shown in the Figures for more clarity as separated by a lineR). In alternative embodiments, cushion 10 includes more or less thantwo regions 108. As a result of the segmented air flow within cushion10, the stability provided to the seated operator is facilitated to beincreased.

In the exemplary embodiment, each region 108 includes a plurality ofcells 60 and 62 that are coupled together in flow communication withonly those cells 14 positioned within that particular region 110 or 112.Accordingly, each region 108 includes at least one inflation/deflationvalve 114 that extends from base 12. Valves 114 may be selectivelyopened and closed to enable fluid to be injected into, or dischargedfrom, cells 14 within the region 108. It should be noted that othervalving arrangements are possible. In the exemplary embodiment, theworking fluid supplied cells 14 is air. In an alternative embodiment,the working fluid is any fluid that enables cushion 10 to function asdescribed herein, including, but not limited to, other gases, fluids, orliquids. Accordingly, in the exemplary embodiment, because cells 14 arecoupled together in flow communication within each specific region 110or 112, when cells 14 are initially inflated, cells 14 within eachspecific region 110 or 112 are each pressurized to approximately thesame fluid pressure.

In the exemplary embodiment, conformal layer 42 is formed integrallywith cells 14 using a conventional dip molding process. Alternatively,conformal layer 42 may be formed using a vacuum molding process or aninjection molding process. In an alternative embodiment, injectionmolded cells 14 are coupled to layer 42 using a known coupling method,such as, but not limited to radio frequency (RE) welding.

In one embodiment, a cover (not shown) fits over cushion 10. The coverprovides an aesthetically pleasing seating surface that facilitatesprotecting cellular cushion 10 and maintaining cells 14 in properposition relative to base 12. As such, the cover facilitates reducingand redistributing pressure to the user from pressure points in theischial regions, and also provides the user with an enhanced sense ofstability.

The above-described cellular cushions provide a user with a sittingsurface that facilitates increasing stability and comfort to the user.More specifically, the cellular cushions each include a conformal layerthat includes a plurality of cells extending therefrom, wherein eachcell extending from the conformal layer is coupled in flow communicationwith every other cell extending from the conformal within its region.The cell dimensions enable a contoured seating surface to be definedthat cradles the seated user and enhances the stability provided to theseated user. As a result, a cellular cushion is provided whichfacilitates increasing the sitting support and stability provided to aseated user in a cost-effective and reliable manner.

Exemplary embodiments of cellular cushions are described above indetail. Although the cellular cushions are herein described andillustrated in association with seated users, it should be understoodthat the present invention may be used to provide cushioning in aplurality of other uses. Moreover, it should also be noted that thecomponents of each cellular cushion are not limited to the specificembodiments described herein, but rather, aspects of each cushion andfabrication method may be utilized independently and separately fromother methods described herein.

While the invention has been described in terms of various specificembodiments, those skilled in the art will recognize that the inventioncan be practiced with modification within the spirit and scope of theclaims.

1. A cellular cushion comprising: a base comprising at least a firstlayer and a second layer, said first layer comprises a substantiallyplanar lower surface and an upper surface that is opposite said lowersurface, said second layer comprises a substantially planar lowersurface and a substantially planar upper surface that is opposite saidsecond layer lower surface; and a plurality of hollow cells coupled tosaid base and extending outwardly from said first layer upper surfacewithin at least one region, each of said plurality of cells within eachsaid region are coupled together in flow communication, each of saidplurality of cells comprises a hollow body portion and an outer surface,said plurality of cells are spaced across said base such that saidplurality of cell outer surfaces cooperate to define a contoured seat,at least one of said plurality of cell outer surfaces is orientedobliquely in a first direction and at least one of said plurality ofcell outer surfaces is oriented obliquely in a second direction that isdifferent from the first direction, at least one of said plurality ofcells having an outer surface oriented only in the first direction andat least one of said plurality of cells having an outer surface orientedonly in the second direction, the contoured seat is configured to cradlea portion of a user, an outer surface of at least some of said pluralityof cells is at least one of oriented obliquely with respect to said baseand is non-planar.
 2. A cellular cushion in accordance with claim 1wherein said plurality of hollow cells further comprise a plurality offirst cells and a plurality second cells, said plurality of first cellseach have a first cross-sectional area, said plurality of second cellseach have a second cross-sectional area that is different than saidfirst cross-sectional area.
 3. A cellular cushion in accordance withclaim 2 wherein said first cross-sectional area of each of saidplurality of first cells is larger than said second cross-sectional areaof each of said plurality of second cells.
 4. A cellular cushion inaccordance with claim 2 wherein said plurality of first cells each havea cross-sectional shape that is different than a cross-sectional shapeof each of said plurality of second cells.
 5. A cellular cushion inaccordance with claim 1 wherein said at least one region comprises atleast a first region and a second region, said plurality of cells withinsaid first region are coupled together in flow communication with onlyother of said cells within said first region, said plurality of cellswithin said second region are coupled together in flow communicationwith only other of said cells within said second region.
 6. A cellularcushion in accordance with claim 5 wherein an operating pressure withinsaid plurality of cells in said first region is controllableindependently of an operating pressure within said plurality of cells insaid second region.
 7. A cellular cushion in accordance with claim 1wherein each of said plurality of hollow cells has a height measuredfrom said first layer upper surface to said cell outer surface, saidcell height is variable within said at least one region.
 8. A cellularcushion in accordance with claim 1 wherein at least some of saidplurality of cell outer surfaces are sloped in a first direction andwherein at least some of said plurality of cell outer surfaces aresloped in a second direction that is opposite said first direction.
 9. Acellular cushion in accordance with claim 1 wherein said at least someof said plurality of cell outer surfaces are sloped towards a centerlineof said cushion, and wherein at least some of said plurality of cellouter surfaces are sloped away from said cushion centerline.
 10. Acellular cushion comprising: a base comprising at least a first regionand a second region, said base further comprising a substantially planarlower surface and a substantially planar upper surface that is oppositesaid lower surface; a plurality of first hollow cells extending outwardfrom said base within said first region; and a plurality of secondhollow cells extending outward from said base within said second region,said plurality of first hollow cells in said first region are coupledtogether in flow communication independently of said plurality of secondhollow cells within said second region, each of said first and secondhollow cells comprises a hollow body portion extending from said base toan outer surface, at least some of said cell outer surfaces are orientedobliquely with respect to said base and are sloped in a first direction,at least some of said cell outer surfaces are oriented obliquely withrespect to said base and are sloped in a second direction that issubstantially opposite said first direction, at least one of saidplurality of cells having an outer surface that is oriented in only thefirst direction and oriented in both the first direction andsubstantially parallel to said base, at least one of said cell outersurfaces comprising a planar portion and an oblique portion that extendsobliquely from the planar portion, said planar portion is substantiallyparallel to said base upper surface.
 11. A cellular cushion inaccordance with claim 10 wherein at least some of said plurality ofcells within said first and second regions further comprise a firstplurality of cells having a first cross-sectional area and a secondplurality of cells having a second cross-sectional area.
 12. A cellularcushion in accordance with claim 10 wherein at least some of saidplurality of cells within said first and second regions further comprisea first plurality of cells having a first cross-sectional shape and asecond plurality of cells having a second cross-sectional shape.
 13. Acellular cushion in accordance with claim 10 wherein said outer surfacesof said plurality of first and second hollow cells define a contouredsurface configured to cradle a portion of a user's buttocks seatedthereon.
 14. A cellular cushion in accordance with claim 10 wherein saidcushion is symmetrical about an centerline axis of symmetry, saidplurality of first hollow cells within said first region are oriented ina substantially mirrored relationship with respect to said plurality ofsecond hollow cells within said second region.
 15. A cellular cushion inaccordance with claim 10 wherein each of said plurality of first hollowcells and said plurality of second hollow cells has a height measuredfrom said base to said cell outer surface, said plurality of cellheights vary within at least one of said first region and said secondregion.
 16. A cellular cushion in accordance with claim 10 wherein saidbase comprises a plurality of layers coupled together.
 17. A cellularcushion comprising: a base comprising at least a first layer and asecond layer, said first layer comprises a substantially planar lowersurface and an upper surface that is opposite said lower surface, saidsecond layer comprises a substantially planar lower surface and asubstantially planar upper surface that is opposite said second layerlower surface; and a plurality of hollow cells coupled to said base andextending outwardly from said first layer upper surface within at leastone region, each of said plurality of cells within each said at leastone region are coupled together in flow communication only with cellswithin said at least one region, each of said plurality of cellscomprises a hollow body portion and an outer surface, said plurality ofcells are spaced across said base such that said plurality of cell outersurfaces cooperate to define a contoured seat, at least one of saidplurality of cell outer surfaces is oriented obliquely in a firstdirection and at least one of said plurality of cell outer surfaces isoriented obliquely in a second direction that is different than thefirst direction, at least one of said plurality of cells having outersurfaces oriented only in the first direction and at least one of saidplurality of cells having outer surfaces oriented only in the seconddirection, the contoured seat is configured to cradle a portion of auser, an outer surface of at least some of said plurality of cells is atleast one of oriented obliquely with respect to said base and isnon-planar, at least some of said plurality of cell outer surfaces aresloped in a first direction and at least some of said plurality of cellouter surfaces are sloped in a second direction that is opposite saidfirst direction, at least some of said hollow cells in said at least oneregion have a non-circular cross-sectional profile.